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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Defects and Properties of Cast Metals IV
Presentation Title Quantifying Pore Evolution during Laser Powder Fusion Using High-speed X-ray Imaging and High Fidelity Multiphase Simulation
Author(s) Chu Lun Alex Leung, Michael Mallon, Dawid Luczyniec, Yuze Huang, Samuel J. Clark, Yunhui Chen, Sebastian Marussi, Lorna Sinclair, Margie P. Olbinado, Elodie Boller, Alexander Rack, Iain Todd, Peter D. Lee
On-Site Speaker (Planned) Chu Lun Alex Leung
Abstract Scope Laser powder bed fusion additive manufacturing (LPBF) produces complex net-shape parts from alloy powders, in a layer-by-layer manner. X-ray imaging studies of pore evolution mostly focus on single-layer tracks on substrates, missing the interaction of the laser beam with pre-existing pores in prior layers. Here, we used an in situ and operando process replicator (ISOPR), synchrotron X-ray imaging and high fidelity simulation to monitor and elucidate the process dynamics during a multilayer build of a Ni-superalloy. We quantify the changes in keyhole geometry, porosity, and remelting zone, as a function of time, layer number, and local layer thickness. These results were compared with a multiphase and multiphysics simulation to reveal the solid-liquid-gas-metal vapour interaction, keyhole evolution mechanisms, melt pool, and porosity. This work highlights the impact of layer thickness on build quality for powder bed fusion processes and suggests ways to mitigate the formation of imperfections.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Solidification, Modeling and Simulation


3D Characterization of Competitive Dendrite Growth and On the Role of Low Angle Grain Boundaries during Solidification of Single Crystal Ni-based Superalloys
Characterization of Second Phase Particles in Twin Roll Cast Aluminum Alloy AA 8011
Controlling Freckle Defect Formation Using Magnetic Fields
Elucidating the Relationship between Arc Behavior and Solidification Defects during Vacuum Arc Remelting of Superalloys
F-26: Correlation between Purification Effect and Surface Segregation of Impurities in Aluminium at High Temperatures
F-27: Modeling the Bonding and Structure of Non-metallic Inclusions within a Nickel Matrix during Forging
F-28: The Mechanical Properties and Microstructural of Cast Zinc though Aluminum Inoculation by Ultrasonic Treatment
Formation Mechanisms of Surface Blistering in AA6xxx Rolled Products: Microstructure Characterization, Ultrasonic Analysis, and Rolling Tests
Hybrid Additive Manufacturing of Island Grain Bicrystals
Improving Material Properties Using Contactless Ultrasonic Cavitation
Measurement and Simulation of Reoxidation Inclusions in Steel Casting
Modelling Concurrent Structural Mechanical Mechanisms in Microstructure Solidification
Modification of Cast and Wrought Aluminum Parts Using Hybrid Laser Hot-wire Manufacturing
NOW ON-DEMAND ONLY – Understanding Effects of Oxide Bifilms on Solidification Microstructures by Multiscale Modeling
Nucleation in Undercooled Melt upon Changes in the Electromagnetic Stirring
Particle Capture Defects in Continuous Steel Casting
Porosity Defects in High Pressure Die Castings: Mechanisms and Uncertainties
Porosity Formation in High Pressure Die Casting: Experiments and Simulations
Probabilistic Multiscale Finite Element Model for Predicting Strength and Fracture Strain of Cast Al-Si-Mg Alloy
Quantifying Pore Evolution during Laser Powder Fusion Using High-speed X-ray Imaging and High Fidelity Multiphase Simulation
Reduced-Order Multiscale Modeling of Elasto-Plastic Cast Alloys with Process-Induced Porosity
Research Progress of Composite Preparation Technology of Bimetallic Wire
The Influence of Environmental and Material Properties Data on Defect Predictions in Computational Fluid Dynamics Simulations of Investment Casting
Uncertainty Quantification of Model Predictions due to Fluid Flow in Laser Powder Bed Fusion of IN625

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